TD27 4-cylinder in-line, OHV, water-cooled has timing belt

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Removal & Installation

2.2L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following: Negative battery cableIntake Air Temperature (IAT) sensor connectorPositive Crankcase Ventilation (PCV) valve and hoseAir intake assemblyUpper radiator hoseAccessory drive beltExhaust front pipeAlternator and bracketsCrankshaft Position (CKP) sensor connectorKnock sensor connectorHeater hosesWater bypass hoseFuel linesEvaporative Emissions (EVAP) valve connectorCanister hoseIntake manifoldEngine wiring harness connectors at left rear of the engine compartmentPower steering pump pressure switch connectorFront coverSpark plugs and wiresCamshaft Position (CMP) sensorValve coverTiming belt. Refer to the Timing Belt unit repair section.Timing belt idler pulleysTiming belt rear coverOil pressure switch connectorCamshaftsCylinder head. Remove the bolts in reverse of the tightening sequence.
   
   Negative battery cable Intake Air Temperature (IAT) sensor connector Positive Crankcase Ventilation (PCV) valve and hose Air intake assembly Upper radiator hose Accessory drive belt Exhaust front pipe Alternator and brackets Crankshaft Position (CKP) sensor connector Knock sensor connector Heater hoses Water bypass hose Fuel lines Evaporative Emissions (EVAP) valve connector Canister hose Intake manifold Engine wiring harness connectors at left rear of the engine compartment Power steering pump pressure switch connector Front cover Spark plugs and wires Camshaft Position (CMP) sensor Valve cover Timing belt. Refer to the Timing Belt unit repair section. Timing belt idler pulleys Timing belt rear cover Oil pressure switch connector Camshafts Cylinder head. Remove the bolts in reverse of the tightening sequence.
   

To install:

Fig. Cylinder head torque sequence-2.2L (VIN D) engine

NOTE Use new cylinder head bolts for assembly.

1. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows: Step 1: 18 ft. lbs. (25 Nm)Step 2: Plus 90 degreesStep 3: Plus 90 degreesStep 4: Plus 90 degrees
   1. Step 1: 18 ft. lbs. (25 Nm)
   2. Step 2: Plus 90 degrees
   3. Step 3: Plus 90 degrees
   4. Step 4: Plus 90 degrees
   
   
2. Install or connect the following: CamshaftsOil pressure switch connectorTiming belt rear coverTiming belt idler pulleys. Tighten the bolts to 18 ft. lbs. (25 Nm).Timing beltValve coverCMP sensorSpark plugs and wiresFront coverPower steering pump pressure switch connectorEngine wiring harness connectors at left rear of the engine compartmentIntake manifoldCanister hoseEVAP valve connectorFuel linesWater bypass hoseHeater hosesKnock sensor connectorCKP sensor connectorAlternator and bracketsExhaust front pipeAccessory drive beltUpper radiator hoseAir intake assemblyPCV valve and hoseIAT sensor connectorNegative battery cable
   
   Camshafts Oil pressure switch connector Timing belt rear cover Timing belt idler pulleys. Tighten the bolts to 18 ft. lbs. (25 Nm). Timing belt Valve cover CMP sensor Spark plugs and wires Front cover Power steering pump pressure switch connector Engine wiring harness connectors at left rear of the engine compartment Intake manifold Canister hose EVAP valve connector Fuel lines Water bypass hose Heater hoses Knock sensor connector CKP sensor connector Alternator and brackets Exhaust front pipe Accessory drive belt Upper radiator hose Air intake assembly PCV valve and hose IAT sensor connector Negative battery cable
   
3. Fill the cooling system.
4. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   Negative battery cable Intake Air Temperature (IAT) sensor connector Positive Crankcase Ventilation (PCV) valve and hose Air intake assembly Upper radiator hose Accessory drive belt Exhaust front pipe Alternator and brackets Crankshaft Position (CKP) sensor connector Knock sensor connector Heater hoses Water bypass hose Fuel lines Evaporative Emissions (EVAP) valve connector Canister hose Intake manifold Engine wiring harness connectors at left rear of the engine compartment Power steering pump pressure switch connector Front cover Spark plugs and wires Camshaft Position (CMP) sensor Valve cover Timing belt. Refer to the Timing Belt procedure. Timing belt idler pulleys Timing belt rear cover Oil pressure switch connector Camshafts Cylinder head. Remove the bolts in reverse of the tightening sequence.
   

To install:

Fig. Cylinder head torque sequence-2.2L (VIN D) engine


NOTE Use new cylinder head bolts for assembly.

1. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows:
   1. Step 1: 18 ft. lbs. (25 Nm)
   2. Step 2: Plus 90 degrees
   3. Step 3: Plus 90 degrees
   4. Step 4: Plus 90 degrees
   
   
2. Install or connect the following:
   
   Camshafts Oil pressure switch connector Timing belt rear cover Timing belt idler pulleys. Tighten the bolts to 18 ft. lbs. (25 Nm). Timing belt Valve cover CMP sensor Spark plugs and wires Front cover Power steering pump pressure switch connector Engine wiring harness connectors at left rear of the engine compartment Intake manifold Canister hose EVAP valve connector Fuel lines Water bypass hose Heater hoses Knock sensor connector CKP sensor connector Alternator and brackets Exhaust front pipe Accessory drive belt Upper radiator hose Air intake assembly PCV valve and hose IAT sensor connector Negative battery cable
   
3. Fill the cooling system.
4. Start the engine and check for leaks.

2.6L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   • Negative battery cable
   • Hood
   • Accessory drive belts
   • Accelerator cable
   • Positive Crankcase Ventilation (PCV) valve and hose
   • Air intake duct
   • Fuel pressure regulator vacuum line
   • Canister hose
   • Brake booster vacuum line
   • Engine wiring harness connectors at right wheel housing
   • Ground cable connector at the intake manifold, starter and firewall
   • Heated Oxygen (HO2S) sensor connector
   • Alternator wiring connectors
   • Oil pressure switch connector
   • Starter motor harness connectors
   • Ignition coil connector
   • Spark plug wires
   • Distributor
   • Exhaust front pipe
   • Exhaust Gas Recirculation (EGR) gas temperature sensor connector
   • Air pump
   • EGR pipe
   • Heat shield
   • Exhaust manifold
   • Throttle Position (TP) switch connector
   • Cooling fan
   • Water pump pulley
   • Power steering pump
   • Intake manifold
   • Crankshaft pulley
   • Front cover
   • Timing belt. Refer to the Timing Belt unit repair section.
   • Valve cover
   • Rocker arms
   • Camshaft
   • Cylinder head

Cylinder head bolt loosening sequence - 2.6L engine

1. To install:
2. NOTE: Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.
3. NOTE: Lubricate the cylinder head bolts with clean engine oil for assembly.
4. Install the cylinder head with a new gasket. Tighten the bolts in sequence as follows:
5. Step 1: 58 ft. lbs. (75 Nm)
6. Step 2: 72 ft. lbs. (98 Nm)

1. Install or connect the following:
2. Camshaft

• Rocker arms
• Valve cover
• Timing belt
• Front cover
• Crankshaft pulley. Tighten the bolt to 87 ft. lbs. (128 Nm).
• Intake manifold
• Power steering pump
• Water pump pulley
• Cooling fan
• TP switch connector
• Exhaust manifold
• Heat shield
• EGR pipe
• Air pump
• EGR gas temperature sensor connector
• Exhaust front pipe
• Distributor
• Spark plug wires
• Ignition coil connector
• Starter motor harness connectors
• Oil pressure switch connector
• Alternator wiring connectors
• HO2S sensor connector
• Ground cable connector at the intake manifold, starter and firewall
• Engine wiring harness connectors at right wheel housing
• Brake booster vacuum line
• Canister hose
• Fuel pressure regulator vacuum line
• Air intake duct
• PCV valve and hose
• Accelerator cable
• Accessory drive belts
• Hood
• Negative battery cable

1. Fill the cooling system.
2. Start the engine and check for leaks.

Remove the serpentine belt, remove the lower crankshaft pulley, place a jack under the oil pan and jack up the engine slightly, remove the engine mount (right top). Remove the timing belt cover, loosen the timing belt tensioner and pull tensioner pulley back toward the rear of vehicle. I like to then tighten the tensioner bolt to hold it in this position, remove and replace belt. If you need to put the engine in time then look at the camshaft there is a small arrow in the center, it lines up with a dot on the end of the cylinder head. The lower timing mark is a small metal tip that sticks out from the lower gear, and it lines up with a notch cut into the front cover just behind the lower gear. Once aligned properly put the belt on the lower gear and without turning the lower gear or camshaft gear pull the belt tight up to the cam shaft the cogs in the belt will line up with the grooves, then place the belt around the water pump drive gear and under the tensioner, then push the belt over all gears by hand without turning the engine. Loosen the tensioner bolt and apply a little pressure toward the front of the vehicle and tighten the bolt. Replace everything else previously removed. Engine should start and run normally.

Try Chilton's or All Data for instructions. This is a 4.5 -5 hour ordeal for a professional and a 2 day mess for an amateur. Plus you must remove the timing belt on the 2.4L 4 Cylinder to get to the pump. Mess up here and you can damage your engine. WATER PUMP is sign with the ITEM 5 in the next diagram...

1. Disconnect the negative battery cable.

This procedure requires removing the engine timing belt and the auto tensioner. The factory specifies that the timing marks should always be aligned before removing the timing belt. Set the engine at TDC on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.

1. Raise and safely support the vehicle to a level that allows access from above and below.
2. Remove the right inner splash shield.
3. Remove the accessory drive belts.
4. Place a drain pan under the radiator drain plug. Drain and properly contain the cooling system.
5. Support the engine using a floor jack and block of wood, then remove the right motor mount.
6. Remove the timing belt, tensioner and camshaft sprockets.

WARNING With the timing belt removed, DO NOT rotate the camshaft or crankshaft, or damage to the engine could occur.

1. Remove the rear timing belt cover to access the water pump.
2. Remove the water pump attaching bolts.
3. Remove the water pump.

Fig. 1: Water pump location on the cylinder block-4-cylinder engines





Fig. 2: Water pump assembly-4-cylinder engines


To install:

1. Thoroughly clean all sealing surfaces. Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough turning bearings, a damaged impeller or sprocket, or a loose or damaged sprocket flange.
2. Install a new rubber O-ring into the water pump.

Make sure the O-ring is properly seated in the water pump groove before tightening the screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.

1. Install the water pump and tighten the bolts to 105 inch lbs. (12 Nm).
2. Using a cooling system pressure tester, pressurize the cooling system to 15 psi and check for leaks. If okay, release the pressure and continue the engine assembly process.
3. Rotate the water pump by hand to check for freedom of movement.
4. Install the rear timing belt cover.
5. Install the camshaft sprocket(s), timing belt and tensioner. DO NOT allow the camshafts to turn while the sprocket bolts are being tightened, in order to maintain timing mark alignment.

WARNING Do not attempt to compress the tensioner plunger with the tensioner assembly installed in the engine. This will cause damage to the tensioner and other related components. The tensioner MUST be compressed in a vise.

1. Install the timing belt covers.
2. Install the right engine mount bracket and engine mount.
3. Remove the floor jack and wood block from underneath the engine.
4. Install the crankshaft damper.
5. Install the right inner splash shield.
6. Lower the vehicle.
7. Install and tension the accessory drive belts.
8. Refill the cooling system using the correct quantity and type of coolant. Bleed the cooling system.
9. Start the engine and check for proper operation.
10. Check and top off the cooling system, if necessary.

2.5L Engine
See Figures 3 through 7

1. Disconnect the negative battery cable.
2. Place a large drain pan under the radiator drain plug. Drain and properly contain the engine coolant.

This procedure requires removing the engine timing belt and the auto tensioner. To help assure proper alignment at assembly, it may be helpful to set the engine at TDC on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.

1. Remove the accessory drive belts and crankshaft damper.
2. Remove the right engine mount. This requires safely supporting the engine with a floor jack and wood block so the mount can be removed.
3. Remove the timing belt covers.
4. Remove the timing belt and tensioner.

Fig. 3: Remove the water pump mounting bolts



Fig. 4: Pull the water pump assembly off of the engine and inlet pipe



Fig. 5: Open the water pump housing and examine for cracks or damage



Fig. 6: Replace the water pump housing gasket using a scraper tool



Fig. 7: Always keep the water pump's mounting bolts lined up with their correct mounting holes

1. Remove the water pump mounting bolts.
2. Separate the water pump from the water inlet pipe and remove the pump.

To install:

1. Thoroughly clean all sealing surfaces. Inspect the pump for damage or cracks, signs of coolant leakage at the vent, and excessive looseness or rough turning bearings. Any problems require a new pump.
2. Install a new O-ring on the water inlet pipe. Wet the O-ring with water to make installation easier. DO NOT use oil or grease on the O-ring.
3. Install a new gasket on the water pump and fit the pump inlet opening over the water pipe. Press the assembly together to force the pipe into the water pump.
4. Install the water pump-to-engine bolts and tighten to 20 ft. lbs. (27 Nm).
5. Install the timing belt and timing belt tensioner. Set the timing belt tension.
6. Install the timing belt covers. Install the right engine mount. Remove the floor jack and engine block from underneath the engine.
7. Install the crankshaft damper.
8. Install the accessory drive belts and set to the proper tension.
9. Connect the negative battery cable.
10. Fill and bleed the engine cooling system.
11. Start the engine and verify proper operation, with no leaks.

Hope this helps (remember to rate this answer).

Look at the where the timing belt is to go. The two gears will have a notch or line and so you make sure that you align them together. If the gears are dirty with caked on oil you should clean it and look for the mark, You only have one mark from each gear. By the way the gears I am talking about is the camshaft and the OHV. Good Luck

install:

1. The cylinder head should be cleaned and inspected prior to installation.
2. Lightly oil all bolt and stud bolt threads before installation.
3. Clean all gasket mating surfaces thoroughly.
4. Install a new head gasket on the cylinder block. WARNING Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.
5. Install the cylinder head on the cylinder block.
6. Tighten the cylinder head bolts in reverse of the removal sequence. Tighten the 2004 cylinder head bolts to 18 ft. lbs. (25 Nm). Tighten an additional 70°, plus 70°, plus another 50°. Tighten 2005 bolts to 18 ft. lbs. (25 Nm). Tighten an additional 60°, plus 60°, plus another 10°.
7. Install the right engine mount. Tighten the engine mount attaching bolts to 22 ft. lbs. (30 Nm).
8. Install or connect the following:
   • Intake manifold
   • Intake manifold support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
   • Throttle cable
   • Surge tank coolant hose
   • Heater hose to cylinder head
   • Fuel feed line at the fuel rail
   • All vacuum hoses
   • Exhaust manifold
   • Rear timing belt cover
   • Timing belt tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
   • Idler pulley. Tighten the bolts to 18 ft. lbs. (25 Nm).
   • Intake and exhaust camshaft gears. Tighten the bolts to 49 ft. lbs. (68 Nm).
9. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear camshaft cover-to-cylinder head seal.
10. Install the valve cover using a new gasket
11. Align the timing marks on the camshaft gears.
12. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
13. Install the timing belt and rotate the water pump clockwise to apply tension to the timing belt.
14. Tighten the water pump bolts to 89 inch lbs. (10 Nm).
15. Adjust the timing belt tension.
16. Install or connect the following:
    • Spark plug wires
    • Upper and lower timing belt coversCrankshaft pulley. Tighten the bolt to 70 ft. lbs. (95 Nm), plus an additional 30°, then another 15°.
    • Accessory drive belt
    • Air cleaner housing
    • Radiator hoses
    • Front splash shield
    • Right front wheel
    • Coolant temperature sensor
    • Fuel feed line from fuel rail
    • IAT sensor
    • Intake manifold pressure sensor
    • DIS coil connector
    • Fuel injector connectors
    • ECM ground terminal
    • Negative battery cable
17. Fill the engine with oil and coolant.
18. Start the engine and check for leak
    

Remove the serpentine belt, remove the lower crankshaft pulley, place a jack under the oil pan and jack up the engine slightly, remove the engine mount (right top). Remove the timing belt cover, loosen the timing belt tensioner and pull tensioner pulley back toward the rear of vehicle. I like to then tighten the tensioner bolt to hold it in this position, remove and replace belt. If you need to put the engine in time then look at the camshaft there is a small arrow in the center it lines up with a dot on the end of the cylinder head. The lower timing mark is a small metal tip that sticks out from the lower gear and it lines up with a notch cut into the front cover just behind the lower gear. Once aligned properly put the belt on the lower gear and without turning the lower gear or camshaft gear pull the belt tight up to the cam shaft the cogs in the belt will line up with the grooves, then place the belt around the water pump drive gear and under the tensioner, then push the belt over all gears by hand without turning the engine. Loosen the tensioner bolt and apply a little pressure toward the front of the vehicle and tighten the bolt. Replace everything else previously removed. Engine should start and run normally. Hope this helps, let me know.

have u bled the cooling system ?warm the car and cut the car off right before the fans come on ,let sit for 30-35 minutes,see if the coolant drops in res. if so repeat process untill coolant stops droping ,then drive car regularly if overheating stops ,but monitor it because it will drop somemore/there has been reports of new and rebuilt water pumps nt having correct propelar mounted on them/ backwards etc. if this helps let me know [email protected]

Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
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Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10.Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
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Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.
6A–30 ENGINE MECHANICAL
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
014RY00043
Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing
Pulley.
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
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Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align the mark (notch) of crankshaft timing pulley
(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
ENGINE MECHANICAL 6A–31
2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 N·m (2.5 Kg·m/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
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